Fluid application device and method

ABSTRACT

The present invention provides a device, a system, and a method for application of fluids.

This application claims the benefit of U.S. Provisional Application No.61/141,540, filed Dec. 30, 2008.

FIELD

The present application relates to an apparatus and method for fluidapplication.

INTRODUCTION

Preparation of patients for various medical procedures, e.g., surgery,typically includes application of a topical solution (or fluid), e.g.,an antiseptic solution, to sanitize the area targeted for medicalprocedures. Topical solutions may be applied to the targeted area bysaturating a sponge-like material with the solution and using a handhelddevice, for example a pair of forceps or a hemostat, to direct thesaturated sponge to the targeted area. The sponges or foam materials aretypically soaked in a fluid contained within an open pan or othercontainer.

In certain instances, existing devices used to apply solutions exhibitvarious disadvantages. For example, typical applicators utilize spongesthat do not retain fluid efficiently, resulting in leakage. As a result,preparing targeted areas for antiseptic cleaning becomes a messyprocedure. In addition, leakage of various fluids onto areas outside ofthe targeted areas can lead to pooling of the various fluids which maycause irritation, discomfort, and/or other undesirable conditions.

Another example of a disadvantage involves the difficulty of dispensinga desired dose of fluid at the targeted area. During fluid application,in certain instances, it may be desirable to control the amount offluid, e.g., antiseptic solution, that is dispensed from the applicator.Because existing applicators dispense fluid inefficiently, however, theprecise amount of solution delivered to the targeted area may bedifficult to determine. This may result in either more or less solutionapplied to the targeted area than is desired. In addition, typicalapplicators utilize foams and/or fluid delivery systems that fail totimely dispense a precise amount of fluid. For example, certainapplicators with internal ampoules that store fluid take time for thefluid to saturate the sponge and thus be available for application tothe patient. This can result in unpredictable and imprecise dispensingof the desired solution.

SUMMARY

In some aspects, the present disclosure is directed to an applicatordevice for applying a fluid. The applicator device may include a handlehaving a proximal end and a distal end. The handle may comprise areceptacle at the proximal end of the handle, the receptacle configuredto receive a packet containing a fluid and facilitate expulsion of thefluid from the packet. The handle may also comprise a flexible lidconfigured to sealingly enclose the packet within the receptacle andconfigured to deflect in response to application of exterior pressureenabling application of the exterior pressure to the packet whendisposed within the receptacle to thereby compress the packet to releasethe fluid from the packet. In addition, the applicator device mayinclude a base at the distal end of the handle. The base may include adistal opening and may be configured to direct flow of the releasedfluid. The applicator device may also include an applicator pad coupledto the base, in fluid communication with an interior portion of thereceptacle, wherein a portion of the pad is inserted within the distalopening of the base, and a portion of the pad is wrapped around anexterior portion of the distal opening of the base.

In certain aspects, the present disclosure is directed to an applicatordevice for applying a fluid, comprising a handle, a base, and anapplicator pad. The handle may include a proximal end and a distal end,and may comprise a receptacle at the proximal end of the handle. Thehandle may be configured to receive a packet containing a fluid andfacilitate expulsion of the fluid from the packet. The applicator devicemay include at least one venting feature configured to allow air flowinto or out of the receptacle. The applicator device may also include aflexible lid configured to sealingly enclose the packet within thereceptacle and configured to deflect in response to application ofexterior pressure, enabling application of the exterior pressure to thepacket when disposed within the receptacle to thereby compress thepacket to release the fluid from the packet. The base may be located atthe distal end of the handle and may include a distal opening. The basemay be configured to direct flow of the released fluid and may include adistal opening in the base. In addition, the applicator pad may beconfigured to be coupled to the base, in fluid communication with aninterior portion of the receptacle via the distal opening in the base.

In some aspects, the present disclosure is directed to a system forapplying a fluid. The system may include a packet containing a fluid andcomprising first and second opposing packet sides defining therebetweena sealed space containing the fluid. The packet may further comprise afrangible area configured to rupture upon compressing the packet torelease the fluid from the packet. The packet may also include acollapsibility feature enabling the first packet side of the packet toinvert from a convex position to a concave position upon compressing thepacket such that the formerly sealed space is substantially completelycollapsed. The system may also include an applicator device comprising ahandle and an applicator pad. The handle may include a proximal end anda distal end, and may comprise a receptacle at the proximal end of thehandle, the receptacle being configured to receive the packet of thefluid and facilitate expulsion of the fluid from the packet. The handlemay also comprise a flexible lid configured to sealingly enclose thepacket within the receptacle. The handle may further comprise a basedisposed at the distal end of the handle and configured to direct flowof the released fluid. The base may include a distal opening. Theapplicator pad may be configured to be coupled to the base, in fluidcommunication with an interior portion of the receptacle via the distalopening of the base.

In certain aspects, the present disclosure is directed to a method forapplying a fluid to a surface. The method may include applying pressureto a flexible outer surface of a handle at a proximal end of anapplicator device to thereby exert pressure on a fluid-filled packetdisposed within the handle to compress a flexible portion of the packet,wherein said pressure may cause a frangible area of the packet torupture to release the fluid from the packet, In some embodiments of themethod, the released fluid may flow through the handle through a distalopening in a base at a distal end of the applicator device to anapplicator pad attached to the base. In certain embodiments of themethod, the applicator pad may be inserted within the distal opening inthe base and wrapped around an outer portion of the distal opening ofthe base. The method may also include contacting the applicator pad ofthe applicator device to a surface to transfer the fluid from theapplicator pad to the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exploded view of an applicator system according toan exemplary disclosed embodiment;

FIG. 2A illustrates a cross-sectional side view of a packet forcontaining fluid, according to certain embodiments;

FIG. 2B illustrates a cross-sectional side view of an assembledapplicator system including the packet of FIG. 2A;

FIG. 2C illustrates a cross-sectional side view of the packet of FIG. 2Ain a collapsed state;

FIG. 2D illustrates a cross-sectional side view of an assembledapplicator system including a collapsed packet;

FIG. 3A is a perspective view of a handle with a receptacle of anapplicator device according to an exemplary disclosed embodiment;

FIG. 3B is a perspective view of a lid corresponding to the receptacleshown in FIG. 3A;

FIG. 3C is a cross-sectional view of an assembled applicator system,according to certain embodiments;

FIG. 4A illustrates a perspective front view of an assembled applicatorsystem, according to certain embodiments;

FIG. 4B illustrates a perspective back view of an assembled applicatorsystem, according to certain embodiments;

FIG. 5A illustrates a front view of a handle for an applicator deviceaccording to certain embodiments;

FIG. 5B illustrates a bottom view of a handle for the applicator deviceshown in FIG. 5A;

FIG. 6A illustrates a front view of a handle for an applicator deviceaccording to certain embodiments;

FIG. 6B illustrates a bottom view of a handle for the applicator deviceshown in FIG. 6A;

FIG. 7A illustrates a front view of an assembled applicator system,according to certain embodiments;

FIG. 7B illustrates a bottom view of the applicator system shown in FIG.7A;

FIG. 8 illustrates a cross-sectional side view of a portion of anapplicator device, according to certain embodiments;

FIGS. 9A-9H illustrate several exemplary disclosed embodiments of a baseof an applicator device;

FIGS. 10A-10F depict a series of steps for creating a rounded applicatorpad from a flat disk of absorbent pad material; and

FIG. 11 illustrates an edge weld between an applicator pad and base ofan applicator device according to an exemplary disclosed embodiment.

FIGS. 12A-12D illustrate several exemplary disclosed embodiments ofapplicator pads.

DESCRIPTION OF VARIOUS EMBODIMENTS

In this application, the use of the singular includes the plural unlessspecifically stated otherwise. In this application, the use of “or”means “and/or” unless otherwise stated. Furthermore, the use of the term“including,” as well as other forms, such as “includes” or “included,”is not limiting. Also, terms such as “element” or “component” encompassboth elements and components comprising one unit and elements andcomponents that comprise more than one unit unless specifically statedotherwise.

The section headings used herein are for organizational purposes only,and are not to be construed as limiting the subject matter described.All documents cited in this application, including, but not limited topatents, patent applications, articles, books, and treatises, areexpressly incorporated by reference in their entirety for any purpose.

The disclosed applicator may be configured to dispense/apply any liquidwith a viscosity suitable to allow passage through, and dispensing by,the disclosed device. In some embodiments, the disclosed applicator maybe utilized to dispense/apply an antiseptic fluid. The term “antisepticfluid,” as used herein, refers to a liquid that, in certain embodiments,may be used to sanitize a region in preparation for various medicalprocedures.

Reference will now be made in detail to the drawings. Wherever possible,the same reference numbers will be used throughout the drawings to referto the same or like parts.

FIG. 1 illustrates an exploded view of a system 10 for applying a fluid.As shown in FIG. 1, system 10 may include a packet 12 configured tocontain a fluid. In addition, system 10 may include an applicator device14 configured to apply a fluid to a surface. Applicator device 14 mayinclude a handle 16. Handle 16 may comprise a receptacle 18 at aproximal end 20 and a base 22 at a distal end 24. Applicator device 14may also include an applicator pad 26 coupled to base 22. Applicatordevice 14 may further include a lid 28 configured to enclose packet 12within receptacle 18.

Packet

Packet 12 may include a proximal end 30 and a distal end 32 and may beconfigured to be inserted into receptacle 18 with distal end 32 ofpacket 12 oriented toward distal end 24 of handle 16, as shown inFIG. 1. The fluid within packet 12 may be expelled by applying anexternal force to packet 12, which may cause packet 12 to burst (e.g.,at a frangible area), allowing (or forcing) the fluid to flow distally,through base 22 and into applicator pad 26.

Packet 12 may be formed in any suitable shape. In some embodiments,packet 12 may have a substantially round shape, as shown in theaccompanying drawings. Packet 12 may be configured to fit within, andcorrespond generally to, the shape of receptacle 18, which may also besubstantially round, as shown. In some embodiments, packet 12 maycontain orienting features to simplify assembly of the components offluid application system 10. For example, packet 12 may have a shapethat corresponds to a mating shape of receptacle 18. In someembodiments, the mating shapes may be asymmetrical to orient packet 12with respect to receptacle 18.

In certain embodiments wherein packet 12 and receptacle 18 have matingsubstantially round shapes (e.g., as shown in FIG. 1), the orientingfeatures may include a structure on receptacle 18 that deviates from thesubstantially round shape of receptacle 18 and a corresponding structureon packet 12 that deviates from the substantially round shape of packet12. For example, the orienting features may include asymmetrical shapes,such as corresponding protrusions on receptacle 18 and packet 12(forming a teardrop-type shape), as shown in FIG. 1. That is, in someembodiments, applicator device 14 may include a packet protrusion 36 onpacket 12, which is configured to orient with corresponding receptaclefeature 34 on receptacle 18.

Mating, asymmetrical shapes, such as teardrops, may not only facilitateassembly by making it readily apparent how packet 12 and receptacle 18should be aligned with one another, but may also ensure that thefrangible area of packet 12 is oriented toward the distal end ofapplicator device 14 so that fluid released from packet 12 may readilyflow to applicator pad 26. For example, in certain embodiments,receptacle 18 may be configured to orient packet 12 with packetprotrusion 36 positioned toward base 22. In such embodiments, packetprotrusion 36 may include the frangible area of packet 12. Thispositioning of the frangible area (i.e., toward base 22) may allow fluidto readily flow, upon rupture of the frangible area, from packet 12toward (and through) base 22 and into applicator pad 26, e.g., due togravity and/or due to squeezing of packet 12 to expel the fluid frompacket 12 and receptacle 18.

As shown in FIG. 2A, packet 12 may include opposing sides 38, definingtherebetween a sealed space 40, which may be fluid-filled. Either orboth of opposing sides 38 may be deformable. The fluid within packet 12may be expelled by applying an external force to opposing sides 38 ofpacket 12, which may cause packet 12 to burst, allowing (or forcing) thefluid to flow distally, through base 22 and into applicator pad 26.

The frangible area of packet 12 may be configured to break open uponapplication of a reasonable activation force (e.g., bysqueezing/compressing packet 12). Although the frangible area may beconfigured to break open upon application of force by a user, packet 12,including the frangible area, may be configured to maintain structuralintegrity during handling, storage, etc., in order to prevent leakage oraccidental opening.

Packet 12 may be formed of any type of material that is suitable forforming a fluid-holding packet with a frangible area. For purposes ofthis disclosure, the term “frangible” shall mean breakable, burstable(as in the case of a flexible packet), or otherwise configured torupture. In some embodiments, the frangible area may be a part of thepacket that has been prepared to have less strength than other portionsof the packet. For example, in certain embodiments, a frangible seal maybe created by sealing the area desired to be frangible at a lowertemperature than required for maximum seal strength. In otherembodiments, a frangible seal may be created by forming the frangiblearea using a specially formulated “peel-able” film that has inherentlylower adhesion.

Packet 12 may be self-draining by way of a two-sided configuration thatallows one side to invert smoothly into the other when packet 12 iscompressed. For example, as shown in FIGS. 2A and 2B, packet 12 mayinclude a first packet side 42 and a second packet side 44. First packetside 42 and second packet side 44 may be sealed together at a sealedportion 46 about the perimeter of packet 12. Packet 12 may be configuredso that, upon compression, first packet side 42 inverts into secondpacket side 44, thus collapsing sealed space 40, as shown in FIGS. 2Cand 2D. Packet 12 may be configured to completely collapse, (and, insome embodiments, remain collapsed), in order to evacuate substantiallyall fluid from packet 12.

Packet 12 may include a collapsibility feature enabling first packetside 42 of packet 12 to invert from a convex position, as shown in FIGS.2A and 2B, to a concave position, as shown in FIGS. 2C and 2D, uponcompressing packet 12 so that the formerly sealed space 40 issubstantially completely collapsed. In some embodiments, first packetside 42 and second packet side 44 of packet 12 may be formed from filmsof differing thicknesses. For example, in some embodiments, first packetside 42 may be formed of a thinner film than second packet side 44 toenable the deformation of first packet side 42 to effectuate inversionof first packet side 42 and thereby the collapse of packet 12.

Alternatively or additionally, first packet side 42 may be sized and/orshaped differently than second packet side 44 to provide thecollapsibility of packet 12. For example, in some embodiments, firstpacket side 42 may include a first central portion 48 and firstperipheral portions 50, and second packet side 44 may include a secondcentral portion 52 and second peripheral portions 54. First packet side42 and second packet side 44 may be sealed to each other at a junctionbetween first peripheral portions 50 and second peripheral portions 54.In certain embodiments, first central portion 48 may have a smallerdiameter (e.g., on the order of tenths or hundredths of an inch) thansecond central portion 52, thereby forming a collapsibility feature,allowing first packet side 42 to nest within second packet side 44, asshown in FIGS. 2C and 2D.

In certain embodiments, the liquid contained in packet 12 may be anantiseptic solution containing an active ingredient. Various antisepticsolution active ingredients are known in the art, including, but notlimited to, ethanol, isopropyl alcohol, other alcohols, and combinationsthereof; benzalkonium chloride; benzethonium chloride; chlorhexidinegluconate; chlorhexidine gluconate with alcohol; chloroxylenol;cloflucarban; fluorosalan; hexachlorophene; hexylresorcinols;iodine-containing compounds; povidone iodine; povidone iodine withalcohol, ethanol, isopropyl alcohol and other alcohols, and combinationsthereof.

In some embodiments, the antiseptic solution may include a biguanidederivative and/or salts thereof, e.g., olanexidine[1-(3,4-dichlorobenzyl)-5-octylbiguanide] and salts thereof, as theactive ingredient, as disclosed, for example in U.S. Pat. No. 5,376,686.In certain embodiments, the topical antiseptic may include olanexidinegluconate.

The antiseptic solution may also incorporate certain surfactants, forexample, polyoxyethylene-based nonionic surfactants, and/or alcohols,for example, ethanol, isopropyl alcohol and other alcohols, and/orwater, in varying amounts. Useful surfactants are known to one skilledin the art, for example, Poloxamer 124 (a/k/aPolyoxypropylene-polyoxyethylene Block Copolymer 124), which isavailable as Polyoxyethylene(20) polyoxypropylene(20) glycol from AsahiDenka Co., Ltd., Japan, POE (9) lauryl ether (available as ‘BL-9EX’ fromNikko Chemicals Co., Ltd., Tokyo, Japan), POE (10) lauryl ether, alsoknown as nonoxynol-10, or NP-10, (available as ‘Emulin NL-100’ fromSanyo Chemical Industries, Ltd., Kyoto Japan).

In certain embodiments, the antiseptic solution may include an activeingredient and a polyoxyethylene-based nonionic surfactant in variousconcentrations. In some embodiments, the polyoxyethylene-based nonionicsurfactant may be present at a concentration of about 0.05 to about 16%(w/v).

In certain embodiments, the topical antiseptic may include a biguanidederivative, and/or salts thereof, in a concentration of about 0.05 toabout 5.0% (w/v of biguanide base). In some embodiments, the biguanidederivative or salt thereof may be olanexidine[1-(3,4-dichlorobenzyl)-5-octylbiguanide] or a salt thereof.

In some embodiments of system 10, applicator device 14 may be providedin ready to use form. For example, applicator device 14 may be stored,packaged, and/or shipped, etc. with applicator pad 26 attached to base22 and with packet 12 enclosed within receptacle 18 by lid 28, as shownin FIG. 2B. (See also FIG. 4A.) In such embodiments, packet 12 may bepre-filled with a fluid, such as an antiseptic fluid, for example.

Receptacle

Receptacle 18 may be configured to receive packet 12 and facilitateexpulsion of the fluid from packet 12. Handle 16 may have features thatfacilitate the delivery of fluid to absorbent pad 26, such as a smoothand tapered neck 56 between receptacle 18 and base 22, which may includea distal opening 57 through which the fluid may flow from receptacle 18to applicator pad 26, as shown in FIGS. 2B and 2D. Receptacle 18 maycomprise a bowl-like shell 58 defining a recess 60, and having a rim 62.(See FIG. 1.) Lid 28 may be sealingly attached to rim 62, e.g., using anheat sealing, radio frequency (RF) welding, adhesive bonding, laserwelding, or any other suitable type of fixation. In some embodiments,receptacle 18 may include energy directors or textured surfaces forultrasonic welding or otherwise joining lid 28 to receptacle 18.

In addition to packet-orienting features such as asymmetrical shapes, asdescribed above, receptacle 18 may include one or more otherpacket-orienting features such as, but not limited to, a depression, awell, ribs, an emboss, a deboss or a series of such elements, to acceptand/or secure packet 12. For example, as shown in FIGS. 2B and 2D,receptacle 18 may include various steps and/or contours that may beshaped to mate with, and/or retain corresponding features on, packet 12.(See also, FIG. 1.)

FIGS. 3A-3C illustrate an embodiment of applicator device 14 includingexemplary packet-orienting features. For example, as shown in FIG. 3A,receptacle 18 may include one or more inner ribs 63, an embossed ridge64, and a de-bossed area forming a well 65. As shown in FIG. 3B, lid 28may be configured to be used with the receptacle shown in FIG. 3A. Insome embodiments, lid 28 may include an indented face 66 which may allowa lid dome 67 of lid 28 to have a lower profile, as shown in FIG. 3B.FIG. 3C is a cross-sectional view of an assembled applicator device 14including the components shown in FIGS. 3A and 3B.

In addition to orienting features, handle 16 may also include one ormore exterior gripping features to facilitate manipulation of applicatordevice 14 by a user. For example, receptacle 18 may include grippingfeatures such as ergonomic shaping and/or sizing, as well asindentations, protruding gripping members, textured strips and/or areas,rubberized material, etc., to promote secure gripping of receptacle 18.In some embodiments, handle 16 may include one or more gripping ribs 68(e.g., on receptacle 18), as shown in FIG. 4B.

In some embodiments, applicator device 14 may include a venting featureconfigured to allow air flow into or out of receptacle 18. Such aventing feature may be configured to limit fluid leaking out of handle16 in undesirable locations, while still allowing for a controlled fluiddelivery to the absorbent pad. For example, in some embodiments, aventing feature may be located at proximal end 20 of handle 16, whereair can pass in and out of handle 16 while the fluid resides at a distalend of handle 16, while applicator device 14 is held upright. In someembodiments, the venting feature may include an area that is leftunsealed at a junction between lid 28 and rim 62 of receptacle 18. Forexample, in certain embodiments, rim 62 of receptacle 18 may include agroove (not shown) over which lid 28 may be left unsealed.

In some embodiments, applicator device 14 may include a venting feature61 configured to allow air flow into or out of receptacle 18. Such aventing feature 61 may be configured to limit fluid leaking out ofhandle 16 in undesirable locations, while still allowing for acontrolled fluid delivery to the absorbent pad. For example, in someembodiments, a venting feature 61 may be located at proximal end 20 ofhandle 16, where air can pass in and out of handle 16 while the fluidresides at a distal end of handle 16, while applicator device 14 is heldupright. In some embodiments, the venting feature 61 may include an areathat is left unsealed at a junction between lid 28 and rim 62 ofreceptacle 18. For example, in certain embodiments, rim 62 of receptacle18 may include a groove over which lid 28 may be left unsealed.

As shown in FIGS. 5A and 5B, in some embodiments, receptacle 18 mayinclude a three-sided channel 69 configured to direct flow of the fluidto distal opening 57 in base 22, which may be slotted to incorporatechannel 69. Also, as shown in FIGS. 6A and 6B, handle 16 can have awider base 22 with a flared distal opening 57. Such a wider base 22 maybe compatible with a wider applicator pad 26. For example, as shown inFIGS. 7A and 7B, applicator device 14 may include a wider base 22 and acorresponding wider applicator pad 26. Features such as channel 69, aflared-type distal opening 57, and a wider base 22 may facilitateincreased flow and/or distribution of fluid to applicator pad 26.

Handle 16, i.e., receptacle 18 and base 22 may be formed using anysuitable process, such as injection molding, machining, and/or any othersuitable manufacturing methods. Features such as open channel 69 and/orflared-type distal opening 57 may facilitate molding of handle 16.Handle 16 may be formed of any suitable material, including, forexample, thermoplastics such as polyester, S-B block copolymer,polyolefins, etc.

Lid

Lid 28 may be configured to sealingly enclose packet 12 withinreceptacle 18. Lid 28 may also be flexible, and thus, configured todeflect in response to application of exterior pressure, enablingapplication of the exterior pressure to packet 12 when disposed withinreceptacle 18 to thereby compress packet 12 to release the fluid frompacket 12. In some embodiments, lid 28 may be configured to distributeforce applied to lid 28. For example, in some embodiments, lid 28 mayhave a dome shape, as illustrated by lid dome 67. (See FIGS. 1, 2B, and3B.)

Lid 28 may be formed by any suitable method, including thermoforming anddie cutting for semirigid embodiments of lid 28. For embodiments whereinlid 28 may be a stretchable material, lid 28 may be die cut stretched.Exemplary materials from which lid 28 may be formed include anymaterials suitable for sealing to receptacle 18. Such materials mayinclude, for example, polyesters, polyolefins, S-B block copolymers,etc.

Lid 28 may be sealingly attached to receptacle 18 using any suitablemethod. For example, lid 28 may be attached to receptacle 18 using heatsealing, adhesive/glue, laser welding, ultrasonic welding, etc.

Base

Base 22 may be located at distal end 24 of handle 16 and may beconfigured to direct flow of fluid released from packet 12 to applicatorpad 26. As shown in FIG. 2B, distal opening 57 may enable the fluid toflow to applicator pad 26 after being released from packet 12. Asdescribed in more detail below, in some embodiments, distal opening 57may be configured to receive a portion of applicator pad 26.

Base 22 may be formed in a variety of shapes and sizes. In someembodiments, the shape and/or size of base 22 may generally correspondto that of applicator pad 26, as shown in FIGS. 6A and 6B. (See alsoFIG. 1.) In other embodiments, applicator pad 26 may have a shape and/orsize that differs from that of base 22.

Base 22 may be oriented at an angle relative to receptacle 18. Forexample, certain embodiments of receptacle 18, e.g., embodiments havinga substantially round shape, as in FIG. 1, may be formed about a centralreceptacle axis 70 through, e.g., the substantially round shape ofreceptacle 18. Central receptacle axis 70 may be oriented at an angle 71relative to an axis 72 perpendicular to a plane 74 (see FIG. 2B)including base 22. In some embodiments, angle 71 may be approximately 90degrees, as shown in FIGS. 1 and 2B, for example. In other embodiments,angle 71 may be any angle within the range of 0 to 180 degrees. Forexample, in FIG. 8, angle 71 is shown at approximately 45 degrees.

As shown in FIG. 8, base 22 may include an inner surface 76 and an outersurface 78 to which applicator pad 26 may be configured to be affixed.In some embodiments, as shown in FIGS. 9A-9H, base 22 may include one ormore perforations 80 over which applicator pad 26 may be configured tobe affixed. Perforations 80 may allow flow of the fluid from receptacle18 to applicator pad 26.

In some embodiments, outer surface 78 may include one or more channels82, as shown in FIG. 9G. Channels 82 may be configured to distribute thefluid to different portions of applicator pad 26. Also, in someembodiments, outer surface 78 of base 22 may be textured, as shown inFIG. 9H. Texture may not only promote attachment of applicator pad 26 tobase 22, but also may facilitate distribution of fluid to differentparts of applicator pad 26.

According to certain embodiments, base 22 may couple to receptacle 18.Base 22 may couple to receptacle 18 in a variety of ways known in themechanical arts, including, but not limited to, attachment by hinges,adhesives, mechanical interlocks, threaded portions, press-fits,friction-fits, interference fits, slide-fits, and/or combinationsthereof. According to other embodiments, base 22 may be integrallyformed with receptacle 18. An integral base/handle combination may bemanufactured by various processes known in the art, including, but notlimited to, molding, injection molding, casting, machining, orcombinations thereof.

In certain embodiments, applicator device 10 may include aninterchangeable attachment between receptacle 18 and base 22. Aninterchangeable attachment may, for example, facilitate the use of baseshaving various shapes and sizes on the same receptacle 18, and viceversa. This may facilitate, e.g., the use of differently-sizedapplicator pads with the same receptacle 18.

Applicator Pad

Applicator pad 26 may be configured to be coupled to base 22, in fluidcommunication with an inner portion of receptacle 18. In someembodiments, as shown in FIG. 2B, a portion of applicator pad 26 may beinserted into distal opening 57 in base 22 and wrapped around an outerportion 84 of distal opening 57. Applicator pad 26 may be attached tobase 22 (e.g., via ultrasonic welding, adhesive, etc.) on outer portion84 of distal opening 57. In some wrap-around embodiments of applicatorpad 26 (e.g., as shown in FIG. 2B), applicator pad 26 may be at leastpartially preformed, e.g., in a shape such as that shown in FIG. 1. Forexample, applicator pad 26 may be molded, cut or shaped, and/orcompressed into such a configuration.

Some wrap-around embodiments of applicator pad 26 may be formed from adisc-shaped pad by inserting a portion of the disc into distal opening57 in base 22 and then wrapping another portion of the disc around outerportion 84 of distal opening 57. FIGS. 10A-10F depict a series of stepsfor creating a rounded applicator pad from a flat disk of absorbent padmaterial. FIG. 10A shows an applicator pad 26 as a flat disk in positionover applicator device 14. As shown in FIG. 10B, the disk-shapedapplicator pad 26 may be compressed and pressed into distal opening 57in base 16. FIG. 10C shows the unconstrained disk in distal opening 57.As shown in FIG. 10D, a tool 85 may then be moved down over the disk.FIG. 10E shows the applicator pad 26 having been pushed around the outerportion 84 of distal opening 57, where applicator pad 26 may be affixedto base 16. FIG. 10F shows tool 85 being withdrawn, leaving the finishedrounded applicator pad 26.

As noted above, like base 22, applicator pad 26 may have any suitableshape and/or size. In certain embodiments, applicator pad 26 may have arounded or substantially spherical or hemispherical shape, as shown inFIGS. 1 and 2B, for example. In some embodiments, applicator pad 26 mayhave alternative shapes, as shown in FIGS. 7A and 7B, as well as FIGS.8, 9A-9H, and 12A-12D. In certain embodiments, base 22 and/or applicatorpad 26 may be generally triangular with rounded edges, as shown in FIGS.9A-9H and 12A-12D. This generally triangular shape may approximate ateardrop shape, as shown. Other exemplary shapes for base 22 mayinclude, without limitation, rectangular, circular, oval, diamond,various polygonal shapes (see, e.g., FIGS. 7A and 7B), and/or complexshapes comprising combinations thereof.

A generally triangular/teardrop shape or diamond shape may enableapplicator device 14 to be used on surfaces having a variety ofcontours. For example, the smaller tips at the corners of the triangleor, for example, a diamond shape (see, e.g., FIGS. 7A and 7B),particularly the distal-most tip 86, may enable access to crevices andsmaller surface features, while the broad, proximal end of applicatorpad 26 may provide a large pad surface to enable application of fluid tolarger, more gently contoured surfaces.

Applicator pad 26 may couple to base 22 using any of a variety ofattachment mechanisms. For instance, applicator pad 26 may be attachedto base 22 using any suitable method, including, for example, adhesivebonding using, for example, medical grade cyanoacrylate, UV cureadhesive, and the like. In some embodiments, applicator pad 26 may beattached to base 22 using RF welding, heat staking, ultrasonic welding,laser welding, mechanical interlocks, hook-and-loop mechanisms (e.g.,Velcro®), threaded pieces, etc., as well as combinations of thesemechanisms. Accordingly, base 22 and applicator pad 26 may each beconfigured for attachment to one another using any of these mechanismsand, therefore, may include the appropriate features (e.g., texture,adhesive, mechanical latching/clamping elements, coatings, etc.) toenable such attachment.

In some embodiments, applicator pad 22 may be attached to base 22 usingan edge weld 87, as shown in FIG. 11. Edge weld 87 may be created byholding handle 16 in a fixture with base 22 facing up, placingapplicator pad 26 on top of base 22, and bringing the ultrasonic horndown over both applicator pad 26 and base 22. In this way, applicatorpad 26 may be wrapped substantially evenly around base 22. During thisprocess, the ultrasonic energy welds the surface of applicator pad 26 tothe edge of base 22 and when the ultrasonic horn is withdrawn, the mainbody of the foam springs back to an uncompressed state.

In some embodiments, applicator pad 26 may include a substantiallyhydrophobic foam. Alternatively or additionally, applicator pad 26 mayinclude a substantially hydrophilic foam. The term “substantiallyhydrophobic foam,” as used herein, refers to a polymer-based foam thatdoes not absorb a substantial amount of water. In contrast, a definitionof a substantially hydrophilic foam is provided below. For purposes ofthis disclosure, a substantially hydrophobic foam shall refer to anyfoam that is not substantially hydrophilic, as defined below.

The term “substantially hydrophilic foam,” as used herein, refers to apolymer-based foam that has an affinity for water. For example, certainembodiments of the invention can utilize a polyurethane foam with anopen-cell pore structure. In certain instances, the substantiallyhydrophilic foam can be designed for a high rate of fluid absorptionsuch as, for example, absorption of around 20 times the weight of thefoam. While not wishing to be bound by theory, a substantiallyhydrophilic foam can demonstrate an affinity for water through one ormore mechanisms including, but not limited to, the presence of polargroups in the polymer chains that can form hydrogen bonds with water orliquids containing active protons and/or hydroxyl groups, a fineopen-cell pore structure that channels liquid into the body of the foamstructure by capillary forces, and/or the addition of absorbingmaterials, such as super absorbers and/or surfactants, to the foammatrix. Substantially hydrophilic foams that can be utilized in certainembodiments of the invention are available from organizations includingthe following: Foamex International Inc. (Media, Pa.), Crest FoamIndustries, Inc. (Moonachie, N.J.), Rynel, Inc. (Boothbay, Me.), Avitar,Inc. (Canton, Mass., USA), Lendell Manufacturing, Inc. (Charles, Mich.,USA), and Copura (Denmark). In addition, certain patents, including U.S.Pat. No. 5,135,472 to Hermann, et al., disclose substantiallyhydrophilic foams that may be utilized in certain embodiments of theinvention. In some embodiments, applicator pad 26 may be formed of aFoamex hydrophobic, reticulated, polyurethane foam.

Applicator pad 26 may include felting or may be non-felted. In addition,applicator pad 26 may include reticulation or may be non-reticulated. Insome embodiments, applicator pad 26 may include multiple pad materials.In such embodiments, combinations of any of the above characteristicsmay be employed. For instance, in one exemplary, multi-material pad, onepad material may be hydrophobic and a second pad material may behydrophilic.

Applicator pad 26 may include a single or multiple layers. In addition,in some embodiments, applicator pad 26 may include slits to facilitatedistribution and/or flow of fluid through applicator pad 26. FIGS.12A-12D illustrate several exemplary embodiments of applicator pad 26having various combinations of the above-listed features. For example,in some embodiments, applicator pad 26 may comprise a single layer andno slits, as shown in FIG. 12A. In various embodiments, applicator pad26 may comprise a single layer, which may include slits 88, as shown inFIG. 12B. As illustrated in FIG. 12B, applicator pad 26 may includemultiple slits. Further, slits 88 may be provided in a pattern. Forexample, FIG. 12B shows a pattern of substantially parallel slits 88oriented at an angle.

In other embodiments, applicator pad 26 may include multiple layers. Asshown in FIGS. 12C and 12D, applicator pad 26 may comprise a base layer90 and a laminate layer 92. Slits 88 may be provided in base layer 90and/or in laminate layer 92. FIGS. 12C and 12D illustrate embodimentswherein slits 88 are provided in at least laminate layer 90. FIG. 12Cshows a pattern of substantially parallel slits 88 similar to those inFIG. 12B. FIG. 12C illustrates a pattern wherein slits 88 are orientedin a generally lateral direction, as opposed to those in FIG. 12B, whichare oriented at an angle. Slits 88 may be disposed at any angle. Inaddition, slits 88 may be provided in any of a number of shapes, such asslit 88 in FIG. 12D, which is generally circular. Slits 88 may also beformed in other various shapes including, but not limited to, ovals,polygons, etc. Slits 88 may be formed in any suitable fashion, forexample, by die/kiss cutting.

In some embodiments, each layer may be formed of a different padmaterial. In various embodiments, applicator pad 26 may include at leastone abrasion layer. In certain applications, an abrasion layer may beused to abrade an area targeted for treatment, for example theepidermis. Abrasion may be performed before, during, and/or afterdispensing the fluid. In certain embodiments, abrasion may cause aloosening of certain biological materials, for example body oils, bodysoils, and/or bacteria, to facilitate treatment of the targeted area.For example, before application of an antiseptic solution, a user mayabrade the epidermis of a patient to loosen bacteria in order to improvethe efficacy of the antiseptic application process. In certainembodiments, an abrasion layer may comprise more than one layer ofmaterial, which may facilitate a greater amount of abrasion and/orabrasion of harder to clean areas.

In certain embodiments, an abrasion layer may comprise various texturesand/or weaves, for example, a gauze-like or foam material. In certainembodiments, an exemplary gauze-like material may be made from variousmaterials that facilitate abrasion, including, but not limited to,cotton, rayon, nylon, and/or combinations thereof. Abrasion layermaterial may be chosen from a number of materials that exhibit varyingdegrees of abrasiveness. For foam materials, the level of abrasivenessmay differ depending on, among other things, the size of thecells/pores. The skin of a premature baby can be thin and fragile, thusan applicator device that comprises an abrasion layer made from nylon orrayon may be preferable to an abrasion layer made from cotton. Incertain embodiments, an abrasion layer may comprise a plurality oflayers of different materials. In some embodiments, for example foamabrasion layers, the abrasion layer may be flame laminated to base 22and/or to applicator pad 24.

As illustrated in FIGS. 12C and 12D, laminate layer 92 (which maycomprise an abrasion layer) may have a shape that generally correspondsto the shape of base layer 90 of applicator pad 26. However, in certainembodiments, laminate layer 92 may have various other shapes including,but not limited to, circular, oval, rectangular, triangular, polygonal,and the like, or complex shapes including one or more of the same.Layers of applicator pad 26 may be attached to one another by variousattachment mechanisms including, but not limited to, adhesive bonding(e.g., using pressure sensitive adhesives), fusion bonding, flamelamination, heat staking, ultrasonic welding, etc. Methods forlaminating and/or attaching various materials to applicator padmaterials, such as foams, are known in the art. For example, U.S. patentapplication Ser. No. 10/829,919, U.S. Provisional Application No.60/464,306, and PCT Serial No. US04/012474 all disclose methods andapparatuses for attaching materials to polyurethane foam.

Components of applicator system 10, including applicator device 14and/or packet 12, may be configured to be sterilized in various waysknown in the art including, but not limited to, exposure to ethyleneoxide (“(Et)₂O”), gamma radiation, electron beam, and/or steam.According to various embodiments, the fluid may also be sterilized invarious ways known in the art, including, but not limited to,filtration, exposure to gamma radiation, electron beam, and/or steam.For example, U.S. Pat. No. 6,682,695 discloses a method for sterilizinga fluid that may be consistent with certain embodiments of theinvention.

Various other embodiments of the invention will be apparent to thoseskilled in the art from consideration of the specification and practiceof the invention disclosed herein. It is intended that the specificationand examples be considered as exemplary only, with the true scope andspirit of the invention being indicated by the following claims.

What is claimed is:
 1. An applicator device for applying a fluid, comprising: a handle having a proximal end and a distal end, the handle comprising: a receptacle at the proximal end of the handle, the receptacle configured to receive a packet containing a fluid and facilitate expulsion of the fluid from the packet; and a flexible lid configured to sealingly enclose the packet within the receptacle and configured to deflect in response to application of exterior pressure enabling application of the exterior pressure to the packet when disposed within the receptacle to thereby compress the packet to release the fluid from the packet; a base extending radially outwards at a non-zero angle from the distal end of the handle and configured to direct flow of the released fluid, the base including a distal opening and an outer wall projecting transversely outwards from the base and circumferentially disposed about the distal opening; and an applicator pad coupled to the base, in fluid communication with an interior portion of the receptacle, wherein a portion of the pad is inserted within the distal opening of the base, and a portion of the pad is wrapped around the outer wall to circumscribe the portion of the pad within the distal opening.
 2. The applicator device of claim 1, wherein the receptacle has a substantially round shape.
 3. The applicator device of claim 2, wherein a central receptacle axis through the substantially round shape of the receptacle is oriented at a non-zero angle relative to an axis perpendicular to a plane including the base.
 4. The applicator device of claim 2, wherein the receptacle has a substantially round shape.
 5. The applicator device of claim 1, wherein the handle comprises one or more exterior gripping features.
 6. The applicator device of claim 5, wherein the one or more exterior gripping features include one or more protruding gripping members, one or more gripping ribs, or one or more textured gripping strips.
 7. The applicator device of claim 1, wherein at least a portion of the applicator device is formed of a transparent or translucent material.
 8. The applicator device of claim 1, wherein the base comprises one or more perforations over which the applicator pad is configured to be affixed, the perforations allowing flow of the fluid from the receptacle through the base to the applicator pad.
 9. The applicator device of claim 1, wherein the base comprises an inner surface and an outer surface to which the applicator pad is configured to be affixed, the outer surface including one or more channels configured to distribute the fluid to different portions of the applicator pad.
 10. The applicator device of claim 1, wherein the base comprises an inner surface and an outer surface to which the applicator pad is configured to be affixed, wherein the outer surface of the base is textured.
 11. The applicator device of claim 1, wherein the applicator pad comprises a hydrophilic foam.
 12. The applicator device of claim 1, wherein the applicator pad comprises a hydrophobic foam.
 13. The applicator device of claim 1, wherein the applicator pad comprises felting.
 14. The applicator device of claim 1, wherein the applicator pad comprises reticulation.
 15. The applicator device of claim 1, wherein the applicator pad comprises multiple pad materials.
 16. The applicator device of claim 1, wherein the applicator pad comprises multiple layers, each layer formed of a different pad material.
 17. The applicator device of claim 1, wherein the applicator pad includes at least one abrasion layer.
 18. The applicator device of claim 17, wherein the at least one abrasion layer comprises one of a textured foam or a woven material.
 19. The applicator device of claim 17, wherein the at least one abrasion layer comprises a gauze material comprising cotton, rayon, nylon, or combinations thereof.
 20. The applicator device of claim 1, wherein the applicator pad is coupled to the base using at least one of adhesives, pressure sensitive adhesives, flame lamination, heat staking, ultrasonic welding, and laser welding.
 21. The applicator device of claim 1, wherein the applicator pad comprises one or more slits configured to promote flow and distribution of the fluid.
 22. The applicator device of claim 21, wherein the applicator pad comprises a pattern of slits.
 23. The applicator device of claim 1, wherein the applicator device comprises a venting feature configured to permit air to enter the applicator device as the fluid flows out of the packet and receptacle into the applicator pad.
 24. The applicator device of claim 1, wherein the lid is configured to distribute force applied to the lid.
 25. The applicator device of claim 24, wherein the lid has a dome shape.
 26. An applicator device for applying a fluid, comprising: a handle having a proximal end and a distal end, the handle comprising: a receptacle at the proximal end of the handle, the receptacle configured to receive a packet containing a fluid and facilitate expulsion of the fluid from the packet, the applicator device including at least one venting feature configured to allow air flow into or out of the receptacle; and a flexible lid configured to sealingly enclose the packet within the receptacle and configured to deflect in response to application of exterior pressure, enabling application of the exterior pressure to the packet when disposed within the receptacle to thereby compress the packet to release the fluid from the packet; a base extending radially outwards at a non-zero angle from the distal end of the handle and configured to direct flow of the released fluid, the base including a distal opening and an outer wall projecting transversely outwards from the base and circumferentially disposed about the distal opening; and an applicator pad coupled to the base, in fluid communication with an interior portion of the receptacle via the distal opening of the base, wherein a portion of the pad is inserted within the distal opening of the base, and a portion of the pad is wrapped around the outer wall to circumscribe the portion of the pad within the distal opening.
 27. The applicator device of claim 26, wherein the venting feature comprises an area at a junction between the lid and the receptacle that is left unsealed.
 28. The applicator of claim 26, wherein the receptacle further comprises a three-sided channel configured to direct flow of the fluid to the distal opening of the base.
 29. The applicator device of claim 1, wherein the receptacle includes a feature adapted to mate with a corresponding feature in a packet configured to be disposed within the receptacle.
 30. The applicator device of claim 1, wherein the outer wall that projects outwards from the base forms a cylindrical projection around the distal opening.
 31. The applicator device of claim 1, wherein the applicator pad has a generally spherical shape.
 32. The applicator device of claim 1, wherein the receptacle has a teardrop shape. 